Arc welding

ABSTRACT

A method of arc welding with a filler material to produce welds of high toughness over a temperature range from -200* F. to +200* F. and of tensile strength exceeding 100,000 pounds per square inch. The welding is carried out in an atmosphere such that the nitrogen and oxygen of the weld metal is minimized and the filler material is very low in phosphorus, sulfur, silicon, nitrogen and oxygen.

United States Patent 72 Inventor Julius Heuschkel [50] Field of Search 29/494, l 1

Irwin, Pa. 504; 75/123, 128;2l9/l37, 145, 146, 74 [21] Appl. No. 682,352 [22] Filed Nov. 13, 1967 References Cited [45] Patented Aug. 31, 1971 UNITED STATES PATENTS Assignee Westinghouse Electric Corporation 3,162,751 12/1964 Robbins 219/137 Pmsburglp 3,139,508 6/1964 Freeman 219/137 x Continuatlon-ln-part of appllcatlon Ser. No. 3,243,231 3/1966 pragetta 7 5 /123 541,889, 18, 1966. now abandoned, j 3,254,991 6/1966 Shimmin 75/123 x which is a continuation-in-part of application Ser. N0. 223,143, Sept. 1962, "W EmmWeF-Carl Quarfmth now abandoned Asszstant Exammer-Brooks H. Hunt Attorneys-A. T. Stratton and C. L. Freedman ABSTRACT: A method of arc welding with a filler material to produce welds of high toughness over a temperature range [54] f fg ggs Fi s from -200 F. to +200 F.- and of tensile strength exceeding a m g g 100,000 pounds per square inch. The welding is carried out-in [52] US. Cl 219/137, an atmosphere such that the nitrogen and oxygen of the weld 75/128 W, 75/128 V, 219/145 metal is minimized and the filler material is very low in [51] Int. Cl B23k 9/24 phosphorus, sulfiir, silicon, nitrogen and oxygen.

0 300 A (9 o o 0 o 2110 I o 260 o MEASURED TRUE .220 11 STRESS AT FRACTURE '5 o x/ //K HIGH PURITY ALLOY x =A|R MELT AND 3 VACUUM MELT 12: I80 g I E '60 0.5% YIELD STRENGTH 1;, 0.2% YIELDI STRENGTH ELA$TlC LIMIT 0R PROPORTIONAL LIMIT( 0.0I%OFFSEI') g I o 12o 5 gig 1 g 1: 6 3 E18 O -EE61 1'1111ov4 g; 40 I I 11 20 11 I 5's 0 1 1 1 1 1 1 '1 1 1 1 1 1 ELONGATION (7.)

STRESS (I000 PSII 0.2 "I. YIE L l 0.5% YIELD s'rnzucm o smsusm El.l\$Tl C LIMIT OR PROPORTIONAL LIMIT( 0.0I% OFFSET) -UN IFORM *ELONGATION SHEEI 1 UF 4 0 2 x O A o?) 0 (9 o 0/ 5 o MEASURED TRUE W x o HIGH PURITY ALLOY 0 1 -AIR MELT AND VACUUM MELT TOTAL REDUCTION ELONGATION AREA I 1 I I I l2 I6 20 i4 ELONGATION (7.)

FIG. I

BR ITTLE FRACTU RE (7o) AND ENERGY (FOOT-POUNDS) PATENTED M1831 \STL 3.602689 SHEET 2 OF 4 ENERGY 4|4 IOO' 'BRITTLE FRAcTuRE 0.2% YIELD WELD SYMBOLS STRESS(P$I) NUMBER o I l2l250 355 o o M52400 4l4 0 l I 4, l "1 2OO -IOO O I00 200 300 I TEST TEMPERATURE ('F) FIG..2.

CHARPY V-NOTCH ENERGY AT +80F(FOOT-POUNDS) noo PATENTED mm m SHEET 3 UF 4 FIG.3.

ARC WELDING CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-impart of application Ser. No. 541,899, filed Mar. 18, 1966 now abandoned which is itself a continuation-in-part of application Ser. No. 223,143 filed Sept. 12, 1962 andnow abandoned.

BACKGROUND OF THE INVENTION This invention relates to arc welding and has particular relationship to the arc welding of high-strength ferrous material. The word strength here has two implications; itsometimes refers to the tensile properties of the material under static conditions and it also refers to the durability of the material under dynamic conditions imposing severe destructive forces on the material.

Typically, high-strength material is used for the hulls of submarines. A submarine which is required to submerge to a great depth must have a hull capable of withstanding the water pressure at the depth. In accordance with the teachings of the prior art, a ferrous material (having a tension yield stress of 80,000 p.s.i.) called I-IY-SO steel is used for submarine hulls. But HY-80 steel is incapable of withstanding the pressure at extreme depths, for example, of the order of 7 miles, without extremes of thickness and weight and it has therefore becomes necessary to develop steels which can withstand these extreme pressures while using thinner sections. A material (having a tension or compressive yield stress of 150,000 p.s.i.) called HY-150 is presently beingconsideredfor this user-Application Ser. No. 275,574 filed Apr. 25, 1963 to Edward T. Wessel assigned to Westinghouse Electric Corporation relates to I-lY-lSO.

High-strength. ferrous materials also have industrial uses. The availability of high-strength steels would make possible the fabrication of such apparatus as fans and pressure vessels with materials of smaller dimensions than are presently used. Conversely, such apparatus, if made of higher strength materials, could be operated at higher speeds or higher pressures than are presently permissible. I-lY-lSO steel or steels approaching I-IY-150 in tensile properties could serve for the making of this apparatus.

With the advent of high-strength materials; such as l-IY-l50, it has become necessary to provide for the joining of by the stress. The tensile properties are evaluated by determining the stress-strain characteristic of the material. At lower stress thestrain is proportional to the stress; at higher stress the strain departs fromproportionality and for still higher stress the material becomes plastic. The PROPORTIONAL LIMIT OR ELASTIC LIMIT is defined as the minimum stress its diameter in the region of the stress is reduced.

such materials in the fabrication of the apparatus. Such apparatus must withstand the dynamic forces to which it is subjected in use and its ultimate test is not only its tensile strength but its durability and its capability for withstanding shocks and impacts, rapid temperature changes and the like. That is, in evaluating joints of such apparatus the word strength is interpreted in its broad sense and not only as meaning tensile strength. It is essential that the joints produced in the fabrication of this apparatus shall have at least the quality of the highstrength material itself, not only as to tensile strength, but also as to toughness and ductility and it is an object of this invention to provide such joints and particularly to provide a method for making such joints.

Since this invention concerns itself with strength of material, it appears desirable at the start to describe how welds are evaluated in terms of the strength, interpreted broadly, of the material fabricated and the present definitions of the various parameters which serve to measure the tensile strength, toughness, and ductility of materials. In evaluating material for welding and the welds produced, weld metal is deposited which may be derived from an electrode or filler metal. In

evaluating any weld made in the practice of this invention, a

block of weld metal is produced and is subjectedto a series of strength tests. Principally, the tensile properties, the ductility, and the toughness of the weld metal are determinedTo determine the tensile properties, the weld metal is subjected to a tensile stress and the strain developed by the stress is measured. Stress is expressed as loading force per unit cross-sectional area and strain as linear-dimension elongation produced The ULTIMATE STRESS is the maximum load resisted by the specimen divided by the original cross-sectional area. The ULTIMATE STRESS is thus an arbitrary magnitude valve.

The TRUE FRACTURE STRESS is the load atwhich fracture occurs divided by the smallest final area in the region of fracture.

The ductility of the weld metal is evaluated by determining the elongation during the stressing and the reduction in area when the fracture occurs.

The UNIFORM ELONGATION is the percent'of increase in length of the specimen which occurs up to the point of UL- TIMATE STRESS.

After the point of ULTIMATE STRESS is reached, the specimen is subjected to the load which had been applied and continues to be elongated until it is ruptured.

The TOTAL ELONGATION is the percent increase in total length of the specimen up to the rupture as compared to its original length.

The AREA REDUCTION is the difference between the original cross-sectional area of the specimen and the final cross section area at the rupture point expressed as a percentage of the original cross section area.

To determine AREA REDUCTION, the minimum area of the ruptured specimen at the rupture point is determined. This minimum area is subtracted from the original cross-sectional, area and the difference divided into the original cross-sec tional area to arrive at the percentage.

The TOUGI-INESS of a specimen is evaluated by measuring the Charpy V-notch impact values. For this purpose the specimen is V-notched-the notch being dimensioned to established standards,and is ruptured in the region of the notch by dropping on the notched specimen, a weight suspended as a mass from a pendulum. The energy required to produce the rupture is measured in foot-pounds. The energy is determined at various temperatures over a wide temperature range since the high-strength material is used not only at room temperature F.) but also at low temperatures, such as occur in outer space and in cryogenic work, The specifications of the Bureau of Ships of the US. Navy demand that the Charpy V-notch energy shall exceed 50 ft. -lbs. at +80 F. and 20 ft. -lbs at 60 F. These are minimal requirements which it is desirable to exceed. Indeed, it is anticipated that the Bureau of Ships specifications will soon demand higher levels. The

minimum level set in arriving at this invention are 60 footpounds at +80 F and 35 foot-pounds at -60 F. These levels may be extrapolated linearly from +200 F. to 200 F. The levels are then in table IB:

' table is a weld having high toughness.

After rupture, the. specimen is studied in the region of the rupture and the proportibn of the ruptured area which is brittle is determined.

The BRITTLE FRACTURE is the percent of brittle area in the specimen after rupture as compared to the total ruptured area. BRITILE FRACTURE is specified in percent at different temperatures in Fahrenheit degrees.

The TOUGHNESS is usually presented graphically. Two curves are plotted; one curve showing the Charpy V-notch energy values in foot-pounds as a function of temperature and the other showing the BRITTLE FRACTURE percent as a function of temperature. The foot-pound curve has a plateau which serves for evaluation purposes. In the BRITTLE FRAC- TURE curve, the temperature at which the BRI'I'ILE FRAC- TURE is zero (FTP) and the temperature at which it is 50 percent (FATI) are both used in evaluation.

Customarily, the material has a designation in terms of its 2/ 10-percent YIELD STRESS. HY-SO is a mate'rial whose 2/ IO-percent YIELD STRESS is 80,000 pounds per sq. inch I-IY150 is a material whose 2/ IO-percent YIELD STRESS is 150,000 pounds per sq. inch. To withstand the stresses at the greatest depths safely the hulls should be fabricated from I-IY-l 50 steel.

It is an object of this invention to provide a method of producing weld joints for high-strength material which joints shall have high tensile properties and also having high toughness throughout the temperature range from room temperature, and above, to very low temperatures. It is an object of this invention to providea method of arc welding in whose welds having high 2/ IO-percent YIELD STRESS, substantially exceeding 100,000 pounds per square inch, and also having high toughness over a wide temperature range, manifested by Charpy V-notch energies exceeding the energies in table IB at the temperatures on this table.

In arriving at this invention welds were made and evaluated as described above. The work plate used was HY-l50 steel having essentially the following composition:

Carbon 0.16% to 0.20% Manganese 0.40% to 0.60% Silicon 0.15% to 0.30% Nickel 3.6% to 4.0% Chromium 1.4% to 1.8% Molybdenum 0.40% to 0.60% \(anadium 0.08% to 0.12% Phosphorous Max. 0.0l% Sulfur sulfur nitrogen Max. 0.010%

Iron Remainder The welds were made using three different arc processes: the metal-inert-gas process, impact called MIG; the tungsteninert gas process, herein called TIG; and the manual electrode process. In the MIG few exhibited good tensileductile, none were tough ans measured bare electrode very lightly coated was used as taught by Ludwig US Pat. No. 2,818,353; in the TIG process, a material for arc welding in the form of a bare clean-surfaced filler wire was supplied; and in the manual process, a flux-coated electrode was used. The identified composition bare electrode, filler wire, and core of the manual electrode were comprised of a series of alloys derived from different melts having different compositions related to HY-l50. Y

The melts were 25-pound ingots of two types; vacuummelted high-purity ferrous alloys and air-melted alloys remelted in a vacuum. The bulk base for the ingot was prepurified iron. The ingots were surface cleansed and cropped to sound metal, then hot forged to 1 4-inch.-sq. billets and hot rolled to 5/ l-inch-diameter rods. The rods were mechanically cleaned and cold drawn to /I.-inch diameter. One-third of the stock so produced by weight was separated outand cold drawn to 0.062-inch-diameterwire. This wire served for automatic argon-shielded consumable electrode (MIG) arc welding. The remaining two-thirds by weight of the Ar-inch-diame ter stock was cut to 14-inch lengths and ground to 3/ 16-inch diameter by. a surface centerless grinder. One-half of the 3/ l 6- inch-diameter stock selected at random served as weld materi In preparing the ingots the phosphorus, sulfur, silicon,

copper (except for two ingots), nitrogen, oxygen and hydrogen contents of the material were as low as the melting technologists were capable of producing, and in preparing the stock for welding these elements were maintained at a minimum. The actual analyses of the various electrodes produced are shown in Table I.

In Table I the various starting materials used are designated by heat numbers in the two extreme left-hand columns. There are nine heat numbers for air-melted ingots; these appear at the bottom of Table I. In carrying out some of the work, these air-melted ingots were remelted in a vacuum arc-melting furnace. .The air-melt heat numbers which were remelted in a vacuum furnace carry designations having a prefix DX. The second column presents the heat numbers for the vacuummelted materials. The welds made with an argon-shielded consumable electrode are designated in the third column under the heading MIG.(Metal Inert Gas). The welds made in an argon-filled chamber are tubulated in the-fourth column headed TIG (Tungsten Inert Gas). The materials used in welding with a stick electrode are tabulated in the fifth, sixth, and seventh columns which are headed 1, 2, 3 to correspond with different coatings on these stick electrodes. The remaining columns carry the alloying components. In each case the remainder is iron. Heat numbers 7560 and 7561,

- wire heat numbers DX285 and DX288, include substantial quantities of copper, 0.88 percent and 1.86 percent respectively.

In table I there are blanks for VM517 to VM541 inclusive for the residual elements Ti, Cb, Zr, W, Co, Al, Pb, B, Sb, Sn, As, Se, and Zn except for VM519 which has 1.33-percent cobalt, and heats VM519 and VM520 which contain 2.10- and 2.17-percent tungsten, respectively. The blanks indicate that the alloys were not analyzed for these residual components; it was assumed that these components would be present in the same quantities as measured for the other alloys VM513 through VM516 inclusive. This assumption is justified because the materials used by the major components of all alloys were the same and it is to be expected that these materials. would have the same composition of residual components.

The heats of table I were prepared to meet requested com- 1 pc itions' as li sted in table 1A. Comparison of tables I and IA 's'ho ws the'residual components in the heats of table I. These components are in the nature of impurities. In addition, the elements phosphorus, sulfur, silicon, (except for heats DX280 to DX403, copper (except for heats DX285, 1 percent, and DX288, 2 percent nitrogen and oxygen are residuals.

The principal or more important strengthening components of the material in table I are cairborlfmanganese, nickel,

I chromium, molybdenum, and vanadium. These materials con- DESCRIPTION OF THE INVENTION An essential part of this invention is a recognition of the fact that the desired combination of weld metal TENSILE STRENGTH, DUCTILITY, and TOUGHNESS can be obc3 5 035 09 8 g 2 a.

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mmmoofi maomeomqm fimgmzoo nmgw zoome 325a naw: HH mama The following table III shows the parameters and the data of side fusion it was detailed technique and not filler material for the welds made by TIG process in an argon-filled chamber. composition that was faulty.

-inch tungperature was between 225 F. In all welds with 22 passes one rod was used for Visual observation of the welds tabulated in table Ill showed All welds tabulated in table III were made with M1 all welds to be sound, but when subjected to radiograph only sten electrode. The interpass tem two of the welds, numbers 413' and 414, were found to be and 250 completely sound. Since most of the defects consisted of lack the first 1 O-passes and twin rods for the remaining 12. In all y bead.

hnique welding in a chamber would metal of the MlG welds. The Charpy W'notch impacts are elevated at +80 F. It is seen that welds 472 and 474 meet the Bureau of Ship 5 requirement that the Charpy V-notch impact exceed 50 foot-pounds, 474 having the highest energy.

75 The following table VII shows the tensile data for the weld metal of the TIG welds which were made in an argon-filled g with a ctrode diameter was three-sixwas carried out with direct cur- 5. se a 3 2 5.... .s... ca 2 a a. N a: is... 9 2 8 8 n 2 5: 5 #2 fi 2 8: B: .Baa N5? 5% 8 h. 2 3 a .35 .0 $33 5. mnssi fi i n. 25.2 5.- 8 E .2 32 .333 88 2 89 .2 816 35 a2 n x fiaufis 88 m 82 on 33 81 5 83a 82 2 a :2 3 Us a: 1 5 88 m 8% a a m 226 g 3 E 5 an n z fiaufls 88 a 82 as 22 0 818 5 28s 82 a efi aafis 88 m 8% 3; 53 g ica $2 n x a aufls 88 m g on 22 2: B13 5. 288 an 52.8: 88 a 85 2: 9 2 2 818 3 288 m2 8S=E EB-E 88 m 8% 2: 33 B73 5 82a 82 a e s aa efifi s 88 m g as 33 g 5 =85 B s wfi axfls B8 2 89 on 32 873 3 3 33 .335: 88 2 8R 2 32 5 3 3 8 n fifi auus 88 2 89 a 3. 5 3 .8 E a wfiwazfia 88 2 89 on 32 872. a. a 2.. 53 a a: 88 2 89m 0 a a 32 815 8. an s wfi aufis 8 2 2: =2 3 3 m8 2 325533 88 2 8R 2: 92 B15 8 a 8...: 3 :23. B 53 88 2 :83 a a 32 3Z5 9 a s sfi ezfis 88 a 8% as 2.242 818 s a :2 a ea a 3 5 e 88 m 8% 3 a 9 2 9 873 9 Na %:5535: 88 m 83 as 22 9 819 5 5 9 8.2:: 88 N 8% as 33 g 5 a 83 can 8 n. 39 P5 2.6 83 N 8% o 8 m 92 9 5 8 .6 a r; .363 88 N Bfi an 226 5 3 3 8a 3 a 5 .33 5 88 a 8am on a 226 2 818 5 Q 2.: 2a 622: 3 HS 88 g u s a 2 26 8 3 2' 8 8: 2a 3 a B5 88 m 8% a s a 92 2 873 2' a 3 88 m 3% o s m 226 818 5 a 2 m 88 a 89m 0 a m 33 B18 3 a wfifiufis g a 8% as 9 2 32 873 3 N n a ea a 63 s 2 5 88 8% a s a 9 2 2: 3 3 3 Q s a ea 3 88 N 8: a a 33 g 3 8 n a .3 Ba 5 5 88 8% a a a 22 2: 818 5 2 5 :5: 88 a 8% a a 9 2 32 818 8 a a a ee 8 5.8.8 2 88 a a a 6 2 9 5 8 5 2m 2 a 88 2 88 a 33 2 238 an 2 53 5.". 83 5 25s as. 5 2 2 a! uc oz 832 s I! 25 32L: E5 5 a: 56

NB MmQ 2H mmwoomm 0H8 I MAH HmQ OZHQHmS I HHH @848 by the technical difficulties of using the chamber and not by the lack of feasibility of the be corrected during the welding operation By welds with 16 passes one rod was used for the first 8 passes and twin rods for the remaining 8. The welds the rate of 6 inch per minute using the sin rate of 5 inch per minute using the twin rods.

The defects in the welds other than 413 and 414 caused produce sound welds. The chamber is sealed 0 and filled with an inert gas to minimize nitro and then the weld is produced bead b in the operation or structure of the electrode wire cannot adopting the proper tec result in radiographically sound welds.

The parameters and the properties for the weldin manual or stick electrode are presented in table lV. The preheat or interpass temperature or making the welds in table IV was F. The ele teenths inch and the welding TABLE IV Weld Radiography No porosity tnree cracks HI'EOSVEI'SE) Slight porosity at ends one crack (transverse; Slight porosity at ends Sound Sound Sound except on last layer Sound Sound Sound Sound Sound Sound Sound Sound Sound Sound Sound Arc Performance Good Good

Good

Good

Good

Good

Good

Good

Good

Good

Good

Good

Good

Good

Good

Good

Beads Joules Per in Travel in/ min Arc Energy Volts Stick Elec.

Weld No.

Vacuu m Wire Heat No;

Orig.

Air -Melt Heat No.

Sound 32333!]DQQDDDQQLSQQDQQQQQZIQDQDQQ I 13!! 232351821.

cocoooneuouooooouooo-eoooooow nouoeomoooooodo o o o o o o c do o dc e v s l E l eeaa' Sound No porosity three cracks (transverse! Sound Sound Sound Sound Sound Sound Sound Sound Sound Sound Sound Sound Sound Sound Sound Sound Good Good

Good

Good

Good

Good

aaaass 7555 DX zao Notes: (I) All welds made in L935; steel grooved plate. 2) lnterpass temperature F. 3l 3/16" Dia. electrodes used with reverse polarity 0. C. current chamber. The last nine rows cover data taken with weld metal from the originally air-melted heats which were remelted in a vacuum. With few exceptions this weld metal had a 2/ l0-percent YIELD STRENGTH exceeding 100,000 pounds per sq. inch. In the case of welds 408, 414, 422, 470, 424, 430 and 471, 150,000 pounds per sq. inch was exceeded. These welds, on the whole, had high ductility, many of them having an elongation exceeding percent and one low-strength weld, 464, having an elongation of 38.2 percent.

The following table VIII presents the impact data for the weld metals of the T10 welds. This impact data is an indication of the toughness of each of the welds. A study of the energy data at +80 for this weld metal reveals truly amazing results. The impacts in most cases exceed foot-pounds and in a number ofcases,359,357,355, 354,407,409,412,414,415, 416, 418, 419, 463, 464, 465, and 467, exceed 100 footpounds. In fact, welds 464 and 467 have an energy of more than 200 foot-pounds. Weld 414 has an energy of 107 foot pounds coupled with a 2/10-percent YIELD STRENGTH of 152,400 pounds per sq. inch. Weld 463 has an energy of 103.5 foot-pounds coupled with a 2/10-percent YIELD STRENGTH of 146,200 pounds per sq. inch.

Table VIIIA below is a composite of tables VII and VIII with the heats, and corresponding welds tabulated in order of 0.2- percent yield strength except for the special welds DX289, DX285 and DX288. The other special welds, DX280, DX286, DX279, DX278, DX287, are not included because their properties are poor as a result of the addition of special elements Ti, Zr, Co and al.

Heats DX285 and DX288 in this table are special heats including copper and substantial silicon and DX289 includes cobalt nd substantial silicon. These elements are shown by tables VII and VIII to have a beneficial effect obscuring the harmful effect of the silicon. It is contemplated that the invenmmmoomm 3% 93m: wmaomaomqm h6g3 in m P 8 9 2. a I 3N CS 3 3 3 3 I 3 m 2 8 a 8H R: I 3 3e 3 3 3 3 I 3 93 w a a R m 32 a I 3m 3m 3: 3H 3 3 I E a; 3 wm 6 0 8 a 8 a I 3 33 33 3 3 3 E a; 05 gm 9 new a? Ea I 33 3N 3 8 3: 3 3 I 3 a; as. 23 E8 E 9% a 33 3 3N 3N Q5 3 3 3 an 3 ea o ER 3 Em. 2 3w 3N EN 3 3 3 i: 3 8.; ED .3 0 3 E2 8 8 33m 3N 3 2 2 2 0 N2 3 -m I a 33 a? N 8 a a s 02 I 3 3N 0 2 3 3 3 l 5 83 N 8 a a a 8 a 3m 3 as 3N 3H 3 3 33 a o R R 9 a a a 33 33 33 3N an 2 N2 8 a; a a. a H 83 Q2 02 3m in 0 3H 3 3 3 38 a a 8 2 8 a a a 3m 3N on 0 9 3 3 3 83 m 8 52 a a a a 3m 9: 3w 3 3 3 2 3 3 a; H 3 s a a 2. Q2 33 3M 3N Cd 3 3 3 E a; as 92 E 92 E3 .32 avg 33 33 3m 3m 3- 3N 3 3 a; N a a 02 062 H 8H 33 EN EN 92 2 3 3 3 a; a 29 a 92 2 E 98 3m 3 3 3 3 3 3 3 a; 2 22 En Em. a a 2% 3m 3N 0 3 3 3 3 3 a m 8 a saw a a a 3m 3 9 2 2 3 2 3 3 3 2; 23 a a a a 02 8M 3N 0 3 3e 3 3 3 3 23 2w 2% 9% a Ea 9% 8 3 3 2 92 3 3 3 3 3 z; a a a a a 8" I. 3 3 3 3 3 3 I an 23 as N m e E3 2. I 3 3N 3N 3H 3 3 I 83 23 06 05 R 8 5 a I am 3N in 9: 0 2 3 I 83 23 o R R 8 a a I 133 33 3a 3 3 2 3 I N8 23 a6 a E E8 Ea 28 I 3 2. 3N o 3 3a 0 2 I 83 23 I a I .I 8e I I I 2 I I 3 I I 83 m I 2 I a I a I I 33 3 I 3 I 83 8?; of NM; o o3- owd2- 8? 8+ NT o 8- a 32 2 23: s25a ew e cszcm 62:23 5 $1 5 s :332

82g 38E c8oz- 82 22 6:3;

W are respectively the ganese, silicon, chromium, el in the weld filler wire. pounds per square inch sub- Y= 6,740+215, 184C+l2,893 Mn+487, 216 Si-l5, 154, 334 (Si)-Cr+34,039 (Cr) +34,-296 Mowherein C, Mn, Si, Cr,- Mo, V, Ni and weight percentages of carbon, man

molybdenum, vanadium and nick Where Y must exceed 100,000

stantially the alloys must be so 5 m3 Mew u g m w mmm mw dYM tt o mm c b a 0 m mun aAt e t r y auo. 2b dvf s m l e k foe ok eh m mmnwn d a md mo m. ,d fi m mm... P 33 me3m o gm e-nhm na hhn CS W d o Al. teueale hO kmnW e s he. ..dh e If na h a0 t B ann Sfifl .lS 0 H3 3 V t c" a Y mm m wwmmmnw t .I V mn w 5 m mm bT norm bS elected as to meet this condigiyen by the following equation as a function of the critical components of the weld filler wire, including silicon: tion. But this alone does not yield a weld metal resistant to as g g s: 8 EU a gm. s fig 3 fig gfig a eis fifi agc asess sagsa s m r H p O 2 o N in acacooco severe mechanical disruptive forces. It is necessary in addition Table VIIID that the alloy content be such that the impact energy limits of table IV at the various temperatures be exceeded. This invention arises from the discovery of an alloy and residual element Fill er Weld content of the material for welding and of the weld metal which meets both conditions.

Welds 419, 415 and 414 ofTable VIIIA have 2 l0 2/10-per- C O6/() l] (mes 0,12 cent YIELD STRESS exceeding 100,000 pounds per square Mn 1.34/315 l.37/3.85 inch substantially (127,700 p.s.i.) and Charpy V-notch ener- Ni 338/332 :32; gies exceeding those presented in table IV at the respective 3: 32:25 l 183 1 5 temperatures in this table. v 0.ll/0.8l d 011/032 The following table VIIIC presents the composition in criti- W cal or important alloy components both of the material and of ggg zg'ggfig 333273533 theweld metalfor the above-mentioned welds. i C" h 0506/0509 Table VIIID shows the range of composition of the alloy and si 0.00710.02l (102/0039 residual components corresponding to table VIIIC. The slant N 0-0004")-0ol3 000310-0036 line may be read through." The remainder isiron in each case.

g omo omoNtn oNNommcv-nmmm moooo I; ggg 0 mm N r r:\|\ @0804 000 H (If D gfi $fi 2 38$& 3888$8$$%3 9$ -l 5 5 go 8$$33R$$QQ $Q$fi$$338$8%8 I E. 2 g 2 E C: OD ooooomommma g; .3 $$S$8$$8$38$3$$82$ e eme e- 2 LI- E 2 3 B 13 u-IQ V v v E"? SS$S8S8S8fi88$S$$$88888888888$$8 a m u-u r-l H ,-a H v-lv-lH u-l H -IHHr- QHFI v-4 0: v-JUJ A o l- 1 g g e 3 :1 H 8888888888c-888Ig l I I I I I I I I I I I c I wml E I t-IHv-Ir-Gv-IHHH H H H a-Q c-l U 3 g 88888888888|888I8o"8l I I I I I I I I I I I I88I ED E l I-IHHHNFIF-IH HHH v-ll-i F1 F4 r-fl H H P I cur-4 m e eae esas a e easesee ee aa e :ECI-

E: 2 i sesame mesa sees as: a esaasa aaz aaee big 0 1-4 r-a v-lv-l -u ---1 |1 HF'r-fl --1|| r-INr-I N F ll- 1 g ncnnmcomcmamcuxmomm mmcmmoowommoamocmmmmoco SE 2334 fi$$$$fi$$fifi$ "&u"\' J 8i m I I5 $3 fizsmasa QQ$$$R3Q$ Q""'"E2r$" :4 a U! 8% E 9's" QEEQ fi$fi$8d$fififi$8- "'"""""-$R E u 5% filkk RfiSHIR" 3 EB3Q%-" 2&3 t: & 8 oooomcmo-mcco olncam Qmooom moo s: e z sezu. 2a:Q2:2aE aRE:m I I I I I I I I I I I zaz g DU) 75 sm see e zs ee esa I I I I I I I I I I I s'e .g 1 O mo H m \O Now-a F2 amaaaaaseseeeseeeeeee-eeeesssseeeeseeee OQOMNIAOOOM r 3 Z :1 25 g o nc=can E-I As shown in Table VIIID a material for use in the practice of welds having substantially the following composition in weight this invention in arc welding in a low-nitrogen, low-oxygen percent are provided in accordance with the invention: surroundings is provided which has substantially the following carb0n...0.068 to 0.12 composition in weight percent. Manganese... l .37 to 3,85

Qarbon...0.06 to 0.11 Nickel...3.4l to 3.42 Manganese...l.34 to 3.75 Chromium...0.45 to 0.68 Nickel...3.28 to 3.32 Molybdenum...l.l5 to 2.65 Chromium...0.45 to 0.68 Vanadinm...0.11 to 0.82 Molybdenum...l.23to2.67 Iron (and residuals) remainder 0.039 The silicon,

. Vanad1um...0.l l to 0.81 phosphorus/sulfur, oxygen and nitrogen contents of these Iron (and residuals) remainder welds is small; silicon 0.02 to 0.039 percent, phosphorus and in which the phosphorus, sulfur, silicon, nitrogen and ox- 0.0007 to Q0009, Sulfur 0-002 to 0008, nitrogen 0-0003 ygen contents are the following low weight percentages: to 0.0036 percent and oxygen 0.0006 to 0.0008 percent. P-0.0005 to0.0006 Silicon content is influenced, in this case, by the plate S-0.00l4 to 0.0019 composition (0.15 to 0.30 percent). Oxygen content is Si 0.007 to 0.022 lowered in the weld metal as a result of reactions with the N 0.0004 to 0.0013 superheated metallic elements. 0 0.0016t0 0.0024 Nickel content ranges are narrow in both the filler metals and in the weld metals because the three heats, having the As shown in Table VIIID a high-strength, high-toughness, p p r l n f o h l m r l f he same H. 1 5 3 R a 9 on 2% 8-02 8- H 98 8 8c M. 2 4h m E 88.: fin m an #8. .H 28. 2. 5% um M W 39v 2 H 5;. R M QM 3 M4- W" mmfi m8. So. 28. in 2 I. on. i; 84 2. H n 0 2 a o w 8E9 "2 m NE. :8. 88 I ,2. m 9. mi 8 QR 9% H 8 8 839 .2" 88 8 a8. 28. I i S. SH a... .n 1 a Q a 8 892 on in .8... a .8--. .m w m w Mu m. H. m. 3. W m MM.. 2 m. w 1000 0N8... 800 n on n .8. m. 36 nun 0' an n pm m: a g

. wuoo .mooqV so 800. In I ,m g6 u a ma mu mu u a g. a 2 M n aw mu w. 1 a: w m .w n m n m mm m n8 38 S n J H H .1 on C Sou .3 .mw 8 w W 3...... 7%. 1. m w. fir $1 .9 q WWW $8 .8 88 W8 H v H m a J 8 v 2 2 so a w 3 Mn wwmm mm MW -5 a Ma. .8. Y 7.. m m mm m M w m .w 0... w 3 5 2 0 8 m n ma 2 32 a 800 .2 I. 1. u a mu. R an n 3 9mm QR o a n wan Zmb 88 38H #8. m%. m8.,v 8 n. m; Bu an 2w 2.. .0 m QR S a: n2 3 85"" m: we. w m .fw H i H mm mm w. m. M. a. M. x. .1 a w H i 2. H H m 5 w: J: 3 9 3 8&2 3 n. mm. ,3... .m. m. M.. o a a a. a. w. v. Mn .3. m 38 88 i 2 8o 2 8 v own H I m. 88 S8 e m. v t n v G and .mm mm m M un a .Mm" m ww 85m m om Ma 28 5 B H MM H." mm. w... 1- 0 2 8 8 #2 852 G M 58 83v Wfl a H 2 80 v Ru S v 3 mm m H M Md t. mm WNW 028 M mm! fiww mfi v c 88. I wm m; 8 m6 0 2 8 3 g m3 0 3 m... 3.. .8. .8... H H w a .2 .8. 2 m. x x. gm 8... w was H".30. n 1 I m 4 3c 3 8 v 2.. nm 3 v 88 S n n o n H on S a 5.. u 5 MN m8. l 2 S N 8o 3 v 8 o 8 0 Q8 1 hfl #8 Jwj 3 8 8 3. n .3 8 a u a. 3 i a. 0 P8 P3 b8 08 o 2-. 2; g I: B 5.. in" 1328 w d 3 1: n 38 35. .8 Z

QHHH mAmEB The individual items of impact data which fail to meet table 18 are underlined. With certain qualifications, it is concluded that VlIIE gives the compositions of material for welding and welds having high tensile strength and high toughness. The compositions may be determined by considering not only table VlllE but also the reasons why the remaining materials and welds of tables VlllA and VIIIB do not meet more than one of the limits of table IB. This can be seen from thefollowing table VIllF.

Table VlllF shows in the third column the number of impact tests which were lower than the limits of table IV for each of the weld metals. The other columns show the significant content of components which caused the failure. For example V507 failed because its Mo was high, V508 because its carbon was low, V514 was marginal (two failures) and it failed because its nickel was low. V5 1 8 had excessive carbon (0.19).

Based on table VllIF it appears that V515 and V517 are marginal at low temperatures, like V514, and should not be considered, in determining the limits of the components of the filler material and weld metal. On this basis the limits, derived from table VllIE,'of a material for welding and of weld metal are presented in table VlIlG.

As shown in Table VlllG a material for arc welding to produce high-tensile-strength, high-toughness welds having the following composition in weight percent is provided for use in the practice of this invention.

Table VIIIG Element Wire Weld C 0.0l/O.l3 0.010/0.13 Mn OBS/3.76 O.97l3.73 Ni 2.64/5.00 2.72/4.67 Cr ODS/1.03 0.01 l/l.08 Mo l.l/2.48 0.80/2.38 V 0.005/0.88 0.0l7/0.9l W 0.02/2.17 0.02/1.56 P 0.005/0.0008 0.005/0.002 S 0.0013/0.0023 0.002/0.005 Cu 0.0003/00017 0.007/0.0l 1 I Si 0.014/0.036 0.02/0.05 N 0.0002/0.001Z 0.0014/0.0026 O 0.0008/0.0044 0.0005/0.0029

The lower limit of the tungsten above is derived from: table VIIIA. This alloy is low in silicon, phosphorus, sulfur, nitrogen. and oxygen. The vanadium over the above ranges, is in addition'limited by the condition that in theabove equation forY, the 0.2-percent YIELD STRESS, the component percentages must be such that Y substantially exceeds 100,000 p.s.i., Y should be greater tan about 120,000.

As shown in VIIIG a high-tensile-strength, high-toughness weld is provided in the practice of this invention having the following composition in weight percent:

. Carbon...0.010 to 0.13

Manganese...0.97 to 3.73

Nickel...2.72 to 4.67

chromium...0.01l to 1.08

Molybdenum...0.80 to 2.38

Vanadium...0.017-to 0.91 Tungsten...0.02 to 1.56

Iron and Residuals Remainder The silicon, phosphorus, sulfur nitrogen and oxygen in this weld islow as shown by table VIIIG.

The following tables IX and X respectively present thetensile data and the impact data for thesticlt electrode welds. While some of these welds had high tensile strengths, and a few exhibited good tensile ducting, none were tough as measured by the Charpy V-notch tests of table IV.

That high strength, coupled with the hightoughness and high ductility, may be achieved only by minimizing residual elements is shown in the following comparison table. XI which i s deriyed from the above. tables.

Table XI compares MIG weld 401 TIG weld 355, and stick electrode welds 377, 385 and 392, all made from wire processed from the same ingot i.e., heat V514. The wires used in-these welds was of the vacuum-treated I-IY-150 type. The column on the extreme right headed by the word' wire" presents the initial composition of the filler wire, the electrode and the cores used. In the wire or electrode the'silicon-is less than 0.02 percent, the nitrogenis 0.0004 percent',,and the oxygen is- 0.0014'percent'. The TIG weld metal-hadasilicon content of 0.02 percent, nitrogen content of 0.0013 percent, and oxygen content of 0.0024 percent. The impact energy at +80 F. for the TIG weld was very high, 151 ft-lbs. The weld had a 0.2-percent YIELD STRENGTH of 12,250 pounds per sq. inch, an elongation of 16.43 percent, andan area reduction of 61.95 percent.- In'every respect this weld metal was highly satisfactory. In the MIG weld metal the silicon was relatively low, 0.03 percent but the nitrogenand oxygen were substantiallyhigher and for the TIG weld, 0.0087 as compared, to 0.0013 and 0.0169 as. compared to 0.0024 respectively, indicating air aspiration into the arc. The energy in the case.of the MIG weldwas only 22 foot-pounds at +80 F. The 2/10- percent YIELD STRENGTH was higher than theTlG weld but the ductility was relatively low. The stickelectrodeweld metal had very high silicon content, between 0.62 percent and 0.65 percent. The nitrogen contents were substantially higher than for the TIG weld metal, and the oxygen content was very much'higher'than for the TIG weld-metal and substantially higher than for the MIG weld metalaTheimpact energy-in one case was substantially higherthan for the .MIG weld metal, and

in the othercases was about the same. Thestrengths were somewhat higher thanfor theMIG weld metal and the ductility was slightly higher. The tableshows that by minimizing the silicon, the oxygen and the nitrogen, high strength coupled withhigh ductility andhightoughness may be achieved.

The novel features characteristic of this invention are dis; closed in detail above.

For a more complete understanding of this invention both as to its organization and as to its method of operation reference is made to the following description taken in connection with the accompanying drawing, in which;

FIG. 1 is a stress-strain characteristic;

FIG. 2 isa graph showing the impact data for weld metal produced in accordance with this invention;

FIG. 3 is a graph showing the relationship between 0.2-percent YIELD STRESS and impact energies for the various weld metal; and

FIG. 4 is a similar graph showing the relationship for which extreme results were achieved.

F 1G. 1 is illustrative of the properties of the weld metal used in evaluating the welds made with the material according to this invention. In FIG. 1 the stress in thousands of pounds per sq. inch is plotted vertically and the strain measured by elongation in percent is plotted horizontally. The full-line curve is a composite obtained by normalizing the date in table VII. The various characteristics of the weld metal are indicated by labeled dots along this full-line curve. The small open circles are points defined by the TRUE FRACTURE and the corresponding TOTAL ELONGATION magnitudes for various weld metals resulting from welds produced with electrodes of high-purity vacuum-melted alloys; the crosses are corresponding points for weld metal made with electrodes of air-melted alloys remelted in a vacuum. The broken-line curves encompass most of these points.

InFIG. 2, impact evaluation curves for'0.2 percent YIELD STRENGTHS 152, 400, 135,500 and 121,250 p.s.i. are plotted. ENERGY infoot-pounds and BRITTLE FRACTURE inpercent are plotted vertically and temperature is plotted horizontally. The BRITTLE FRACTURE curves are the curves which have a plateau intersecting the point 100 on the left. The other curves present the foot-pounds impact energy as a function of temperature. The curves are labeled to show the weld metal to which theycorrespond. From the curves plotted from the data derived in testing weld metal 414 it is seen that this weld metal, which has a YIELD STRENGTH of 152,400 pounds per sq. inch, has an impact plateau at 106 foot-pounds for F. and maintains substantial impact energy at low temperatures. This metal is very tough and has high tensile strength. The BRITTLE FRACTURE percentage is zero at' about 12 F. and 50 percent about 54 F. Weld metal-4l4- appears to be highly satisfactory from the standpoint of strength and toughness.

In FIG. 3 0.2 percent YIELD STRESS is plotted horizontally and Charpy V-notch energy vertically for the TIG weld metals. The various points bear a label indicating the melt from which the filler was made. The arrows show the trend in temperature as the impact values increase. The three points 

1. The method of arc-welding work of low-alloy steel, having a 0.2 percent yield stress exceeding about 100,000 pounds per square inch and Charpy V-notch minimum energy levels as defined in table IB hereof, said work having a low oxygen, nitrogen and silicon content, with a filler metal of low-alloy steel to produce welded joints of 0.2 percent yield stress exceeding about 100,000 pounds per square inch and Charpy V-notch minimum energy levels as defined in table IB hereof, the said method comprising producing a welding arc at said work to melt said metal and depositing said metal as weld metal on said work, in a welding atmosphere such as to maintain the oxygen, nitrogen content of said weld metal at a minimum, said filler metal having a low phosphorus, sulfur, oxygen, nitrogen, and silicon content of the order set forth. P - 0.0005 to 0.0006 S-0.0014 to 0.0019 O - 0.0016 to 0.0024 N - 0.0004 to 0.0013 Si - 0.007 to 0.021
 2. The method of claim 1 wherein the arc welding is carried out be welding with a nonconsumable electrode in an atmosphere of inert gas and the filler, wire is a filler wire supplied to the arc.
 3. The method of claim 1 in whose practice the phosphorous, sulfur, silicon, nitrogen, and oxygen in the filleR wire are maintained within the following limits in percent of the weight of the filler material: - about 0.0005 to 0.0006 S- about 0.0014 to 0.0019 Si - about 0.007 to 0.021 N2 - about 0.0004 to 0.0013 O2 - about 0.0016 to 0.0024.
 4. The method of claim 1 in whose practice the phosphorus, sulfur, silicon, nitrogen, and oxygen in the filler wire are maintained within the following limits in percent of the weight of the filler material: P - about 0.0005to 0.0008 S - about 0.0013 to 0.0023 Si - about 0.014 to 0.36 N2 - about 0.0002 to 0.0012 O2 - about 0.0008 to 0.0044.
 5. The method of claim 1 wherein the filler metal has a carbon content of 0.06 to 0.11. 